Two-piece form insert for concrete structures and a mounting tool for installing the insert in a concrete form

ABSTRACT

A molded plastic insert is intended for use in a concrete form for making a socket in a concrete structure adapted for engagement with a tool. The insert has an interior bore with an open end, a closed end and two opposed channels extending longitudinally from the open end toward the closed end to receive flanges of a tool. Each longitudinal channel terminates near the closed end in a generally annular channel adapted to receive one of the tool flanges such that the tool can be prevented from extraction from the insert by a quarter turn rotation of the tool flanges in the annular channels in the manner of a bayonet lock. The insert has on an exterior surface one or more generally annular ribs and opposite longitudinal projections corresponding to the interior longitudinal channels. The insert is constructed from two essentially identical molded half pieces.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority of U.S. Provisional Application No. 60/635,471, filed Dec. 13, 2004.

FIELD OF THE INVENTION

The invention relates to the general field of forming of concrete structures, and more particularly to an insert that is placed into the form to create a socket to receive tools to facilitate lifting and handling of the concrete structure, and to a mounting tool for supporting the insert on a concrete form wall.

BACKGROUND OF THE INVENTION

Form inserts are used in the forming of concrete structures to create sockets for various lifting and handling tools, such as rings or hooks, to facilitate handling of the concrete structure. A lifting tool is usually a steel rod with a ring or hook at one end and a pair of opposed flanges at the opposite end to engage inside the socket. The inserts which create the sockets usually include exterior formations, such as annular ribs or flanges, around which the wet concrete flows when it is poured into the form. When the concrete hardens, these exterior formations engage the surrounding concrete to increase resistance against a “pull-out” separation of the insert from the concrete structure. The inserts usually have a central cylindrical bore with two opposite longitudinally-extending channels to receive a lifting tool. The longitudinal channels terminate in generally annular channels. The lifting tool is engaged into the socket by inserting the tool flanges in the longitudinal channel until reaching the annular channels, then rotating the tool a quarter turn, locking the tool in the socket.

The insert may be supported on the wall of a concrete form by a mounting tool having flanges similar to the lifting tool to engage with the same channels in the insert that are engaged by the lifting tool. The mounting tools include springs to pull the insert toward a sealing surface of the mounting tool to provide a seal around the open end of the insert to prevent concrete from entering the interior bore.

Form inserts are often made of molded plastic. The molding operation to mold a form insert with annual exterior ribs and the interior channels as described above usually require complex multiple-step movements of the molding machinery.

SUMMARY OF THE INVENTION

One aspect of the invention is a molded plastic insert that is constructed from two essentially identical half pieces that are mated together to form the whole. Essentially identical half pieces can be molded in simple plastic molds, thus eliminating some of the movements of a molding machine that are required if the insert were molded as a whole. It is preferred that the half pieces be entirely identical.

A preferred insert intended to create a socket for a lifting tool has an interior bore with an open end, a closed end and two opposed channels extending longitudinally from the open end toward the closed end that are adapted to receive flanges of a lifting tool. Each of the longitudinal channels terminates near the closed end in a generally annular channel that is adapted to receive one of the lifting tool flanges such that the lifting tool can be locked in the insert by a quarter turn rotation of the lifting tool flanges in the annular channels. The insert has an exterior surface with one or more generally annular ribs and two opposed longitudinal projections that correspond to the interior longitudinal channels. The half pieces are connected to each other along mating edges that run transversely along respective centerlines of the longitudinal projections. Thus, each of the half pieces includes an inner surface defining half of the interior bore, half of each of the opposed longitudinal channels, and one of the annular channels.

In another aspect of the invention, the insert has an interior bore with an open end, a closed end and two opposed channels extending longitudinally from the open end toward the closed end adapted to receive flanges of a lifting tool. Each of the longitudinal channels terminates near the closed end in a generally annular channel that is adapted to receive one of the lifting tool flanges such that the lifting tool can be prevented from extraction from the insert by a quarter turn rotation of the lifting tool. Each of the opposed longitudinal channels is also intersected by a second generally annular channel adjacent the open end of the bore. The second annular channels are adapted for engagement by flanges of a mounting tool to hold the insert in place on a concrete form wall. Preferably, the second channels extend substantially helically to the bore for a thread-like engagement between the mounting tool and the insert in which the insert is drawn against a sealing surface of the mounting tool to provide a seal for the bore. The helical channels eliminate the need for springs in the mounting tool.

Another aspect of the invention is a system that includes a mounting tool for holding a form insert on a form wall during formation of a concrete structure. The insert has annular channels adapted for engagement with the mounting tool. The mounting tool includes a portion that is fixed on the form wall and a rotable portion. The rotatable portion includes locking flanges adapted to be received by the annular channels of the insert. The fixed portion includes holding flanges to keep the insert from rotating with respect to the tool. The annular channels of the insert extends substantially helically, such that the relative rotation between the insert and the rotatable portion of the locking member draws the insert and mounting tool towards each other to form a seal barrier to keep concrete from entering the insert bore.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a two-part insert for lifting concrete, and a mounting tool for installing the insert, according to the invention.

FIG. 2 is a perspective view of the two-part insert of FIG. 1.

FIG. 3 is a side elevation view of the two-part insert of FIG. 1.

FIG. 4 is a section view of the two-part insert of FIG. 1 taken along the line 4-4 in FIG. 3.

FIG. 5 is a perspective view of one of the identical insert half pieces of the insert of FIG. 1.

FIG. 6 is an outer side elevation view of the insert half piece of FIG. 5.

FIG. 7 is an inner side elevation view of the insert half piece of FIG. 5.

FIG. 8 is a partial section view of the insert of FIG. 1 showing mating engagement between end walls of the identical insert half pieces.

FIG. 9 is a perspective view of the insert of FIG. 1 engaged by a lifting tool, the insert shown with one of the insert half pieces removed for clarity of view.

FIG. 10 is a perspective view of the mounting tool of FIG. 1.

FIG. 11 is an exploded side view of the mounting tool of FIG. 1.

FIG. 12 is a perspective view of the insert and mounting tool of FIG. 1 with the mounting tool in an unlocked condition with respect to the insert, the insert shown with one of the insert half pieces removed for clarity of view.

FIG. 13 is a perspective view of the insert and mounting tool of FIG. 1 with the mounting tool in a locked condition with respect to the insert, the insert shown with one of the insert half pieces removed for clarity of view.

DESCRIPTION OF THE INVENTION

Referring to the drawings, where like numerals identify like elements, FIG. 1 shows an insert 10 and a mounting tool 12 for installing the insert 10 in a concrete form. The insert 10 is intended to make a socket in the concrete structure for engagement by a tool such as a lifting ring or hook. The mounting tool 12 holds the insert 10 in position on a wall of the concrete form during pouring of the concrete structure. The mounting tool 12 also provides a seal between the insert 10 and the mounting tool 12 to prevent concrete from entering the insert.

The Insert:

The insert 10 includes essentially identical half pieces 14 to facilitate molding of the insert from a plastic material in a one step molding process. The term essentially identical is used because the invention could be embodied by using two mold cavities that are essentially identical but with some minor or trivial differences that do not detract from the function or prevent them from being mated together to form the insert. Preferably, however, the half pieces are identical in the sense that they can be produced from the same mold cavity or identical mold cavities.

Referring to FIG. 2-4, the insert 10 includes an elongated interior bore 16 for receiving the mounting tool 12 during pouring of the concrete structure and, later, for receiving a tool to facilitate lifting or handling of the concrete structure. The interior bore 16 is generally cylindrical and extends from an open end 18 to an opposite closed end 20. The insert 10 also includes longitudinally-extending channels 22 on opposite sides of the interior bore 16 for receiving locking portions of the mounting tool 12 and a lifting tool.

The insert 10 includes a first pair of locking channels 24 in the interior bore 16 located adjacent the closed end 20, which may at times be referred to herein as the distal end of the insert 10. The first pair of locking channels 24 are generally annular and are adapted for receipt of a lifting tool 26 (See FIG. 9). Each of the locking channels 24 intersects and communicates with one of the longitudinally-extending channels 22 of the insert 10. The locking channels 24 receive peripheral locking flanges 27 of the lifting tool 26 via the longitudinally-extending channels 22 by applying a one-quarter turn rotation of the lifting tool 26 in the nature of a bayonet lock.

The insert 10 also includes a second pair of locking channels 28 in the interior bore 16 located adjacent the open end 18 of the insert 10, which may at times be referred to herein as the proximal end of the insert 10. The second pair of locking channels 28 is adapted for engagement by the mounting tool 12 to secure the insert 10 inside a concrete form and prevent its rotation. Similar to the first pair of locking channels 24, each of the second pair locking channels 28 intersect and communicates with one of the longitudinally-extending channels 22 As shown in FIGS. 3, each of the second pair locking channels 28 is generally annular, but preferably advance in substantially helical fashion to provide for a thread-like engagement with the peripheral locking flanges of the mounting tool 12 and draw the insert 10 toward the mounting tool 12.

Referring to FIGS. 5-7, each half piece 14 includes a body wall 30 having an intermediate portion 32 that defines half of the generally cylindrical configuration of the interior bore 16. The body wall 30 also includes first and second side portions 34, 36 on opposite sides of the intermediate portion 32 forming half of the longitudinally-extending channels 22 of the insert 10. As shown in FIG. 4, the side portions 34, 36 of the insert half pieces 14 are generally C-shaped. The side portions 34, 36 are adapted to provide for engagement of the first side portion 34 of each of the half pieces 14 with the second side portion 36 of the other half piece 14.

The first side portion 34 of the insert half piece 14 include segments 38, 40 respectively defining an end wall and one of the side walls of the longitudinally-extending channels 22. The second side portion 36 of the insert half piece 14 includes segments 42, 44. Segment 44 of the second side portion 36 forms the other side wall of the longitudinally-extending channels 22. Segment 42 of the second side portion 36 of each insert half piece 14 overlaps segment 38 of the first side portion 36 of the other insert half piece 14 to provide a nested engagement between the side portions 34, 36. A recess 46 is formed on the inner surface of the second side portion 36 of each half piece 14 adjacent the junction of segments 42, 44 in which a terminal edge of segment 38 of the first side portion 34 of the other half piece 14 is received.

Each insert half piece 14 may also include a longitudinally-extending flange 48 connected to an outer surface of segment 38 of the first side portion 34. The flange 48 includes a plurality of slot openings 50. The slot openings 50 of each half piece 14 receive tab projections 52 aligned with the openings 50 along an edge of segment 42 of the second side portion 36 of the other half piece 14. The engagement between the tab projections 52 and the slot openings 50 serves to limit relative axial movement between the insert half pieces 14. The pieces may alternatively be heat welded or adhesively attached to each other.

Referring to FIG. 5, the external surface of each insert half piece 14 may include a plurality of generally annular ribs 54. The annular ribs 54 provide bearing surfaces for engagement with surrounding concrete of a concrete structure, thereby increasing the force required for a pull-out separation of the insert 10 from the concrete. The formation of the first and second pairs of locking channels 24, 28 on the inner surface of the insert half pieces 14 creates projections 56, 58, respectively corresponding to the channels 24, 28, on the external surface of the half pieces 14. The external surface of each insert half piece 14 may also include a longitudinal reinforcement rib 60 extending between two of the annular ribs 54 adjacent the open end of the insert 10. Connected to annular ribs 54 at its opposite ends in this manner, the longitudinal rib 60 functions like a strut or web to axially strengthen the body wall 30.

Referring to FIG. 5, each insert half piece includes a transverse wall 62 at the distal end oriented substantially perpendicular to a central axis of the insert 10. The transverse wall 62 of each half piece 14 is adapted to engage the transverse wall 62 of the other half piece 14 to form an end wall that encloses the distal end of the interior bore 16. The transverse wall 62 of each half piece 14 includes edge portions 64, 66 respectively connected to segment 38 of the first side portion 34 and segment 42 of second side portion 36. Each of the edge portion 64, 66 occupies approximately one-half of the edge of transverse wall 62.

Referring to FIG. 4, segment 38 of first side portion 34 extends to a distance from segment 40 that is greater than the distance to which segment 42 extends from segment 44 of the second side portion 36. As a result, the edge portion 64 connected to the first side portion 34 projects to a distance from segment 40 that is greater than the distance that edge portion 66 projects from segment 42. Because the edge portions 64, 66 project to different distances in this manner, the edge portion 64 of each half piece 14 overlaps the edge portion 66 of the other half piece 14. This overlap between the edge portions 64, 66 is shown in the section view of FIG. 8. The edge portion 66 of each half piece 14 defines a recess 68 on the inner surface of the edge portion in which the edge portion 64 of the other half piece is slidingly received in nested fashion.

The Mounting Tool:

The mounting tool 12 is shown in greater detail in FIGS. 10 through 13. The mounting tool 12 includes rotatable and fixed portions 70, 72 that can rotate with respect to each other about an axis, A. The rotatable portion 70 includes a locking plate 74 operable connected to a lever 76. The locking plate 74 includes flanges 78 extending from a periphery of the locking plate 74 that are adapted for engaging receipt in the second locking channels 28 of the insert 10. As described below in greater detail, the rotation of the rotable portion 70 with respect to its fixed portion, 72 of the mounting tool 12 moves the locking flanges 78 into the insert locking channels 28, drawing the insert 10 toward the mounting tool 12.

The lever 76 includes a drive portion 80 to which the locking plate 74 is secured, and a handle portion 82 for rotating the drive portion 80 and locking plate 74. The locking plate may be welded to the lever 76. The lever 76 may also include a metal washer 84 secured to the lever 76 towards the juncture between the drive portion 80 and the handle portion 82. The washer 84 may also be secured by welding.

The fixed portion 72 of the mounting tool 12 includes a positioning plate 86 having two opposed flanges 88 extending from its periphery and adapted to be received in the longitudinal channels 22 of the insert. The positioning plate 86 is located adjacent the locking plate 74 of the first portion 70. Thus, the flanges 88 of the positioning plate 86 are received within the longitudinally-extending channels 22 of the insert to inhibit rotation of the insert when the flanges 78 of the locking plate 74 are turned into the second locking channels 28 in the manner described below.

The fixed portion 72 of the mounting tool 12 may include a locator tube 90 defining a substantially cylindrical interior in which the positioning plate is received. The locator tube 90 includes a pair of end notches 92 on opposite sides of the locator tube to accommodate the peripheral flanges 88 of the positioning plate 86 that extend outwardly from the locator tube 90. The notches 92 have a width substantially matching that of the positioning plate flanges 88 such that relative rotation between the positioning plate 86 and the locator tube 90 is inhibited.

The fixed portion 72 of the mounting tool also includes a housing body 94 defining an interior bore 96 through in which the locator tube 90 is received such that opposite ends of the locator tube 90 extend from forward and rearward ends of the housing body 94. A stop ring 98 and a resilient seal 100 (such as a neoprene rubber washer) are received on the outer surface of the locator tube 90 such that the resilient seal 100 is located between the stop ring 98 and the rearward end of the housing body 94. The stop ring 98 is secured to locator tube 90, preferably by welding, such that relative axial movement between the locator tube 90 and housing body 94 is inhibited. The housing body 94 also includes internally threaded openings 102 on opposite sides of the body 94 for receiving set screws (not shown), or other threaded elements, for securing the locator tube 90 and housing body 94 to each other such that relative rotation is prevented.

The drive portion 80 of lever 76 is received within the interior of the locator tube 90, and in central apertures in each of the positioning plates 86 and the locking plate 74 such that the locking plate 74 and the handle 82 of lever 76 are respectively located forwardly and rearwardly of the housing body 94. A metal thrust plate 104 is received within the interior of the locator tube 90 at the rearward end of the tube 90. The thrust plate 104 has a central aperture in which the drive portion 80 of the lever 76 is received to provide a support point for the lever 76. The thrust plate 104 is preferably secured within the interior of the locator tube 90 by welding to prevent relative rotation between them.

A second resilient sealing ring 106, preferably made from neoprene rubber, includes a central aperture for mounting the sealing ring 106 on the outer surface of the locator tube 90 at a forward end of the tube 90. The sealing ring 106 includes opposite notches for accommodating receipt of the peripheral flanges 88 of the positioning plates 86. The sealing ring 106 defines a substantially planar sealing surface 108 adapted to contact a sealing surface 110 of the insert defined by annular ribs 54 of the insert half pieces 14 located at the open end of the insert 10. The resilient sealing ring 106 is adapted to compress and form a concrete barrier seal when the insert 10 and mounting tool 12 are drawn towards each other by the engagement of the locking plate 74 to the insert 10.

The fixed portion 72 of mounting tool 12 also includes a support plate 112 adapted for fixed connection to an outer surface of the housing body 94. The support plate 112 includes elongated notches 114 located on opposite sides of the housing body 94 for securing the support plate 112 in a fixed position on a concrete form wall (not shown). As shown in FIG. 10, the notches 114 of the support plate 112 are reversed in direction with respect to each other to provide for pivoting engagement or disengagement of the support plate 112 to a concrete form wall.

The mounting tool 12 is shown in FIG. 12 engaging the insert 10 such that the peripheral flanges 88, 78 of the positioning plates 86 and the locking plate 74, respectively, are located within the longitudinally-extending channels 22 and the sealing surfaces 108, 110 are in contact with each other. The mounting tool 12, however, is in an unlocked condition in which the insert 10 can be pulled off of the mounting tool 12 by axially withdrawing the insert 10 from the mounting tool 12.

In FIG. 13 the mounting tool 12 is shown in a locked condition with respect to the insert 10. The rotating portion 70 of the mounting tool 12 has been rotated about a quarter turn with respect to the second portion 72 using lever 76 such that the peripheral flanges 78 of the locking plate 74 are driven into the locking channels 28 of the insert 10. Because of the helical configuration of the locking channels 28, the resulting thread-like engagement between the locking plate 74 and the locking channels 28 draws the insert 10 toward the mounting tool 12. The resulting contact force between the sealing surface 108 of the mounting tool 12 and the sealing surface 110 of the insert 10 compress the sealing ring 106 and seals the open end of the interior bore of the insert 10 against concrete entry.

The foregoing describes the invention in terms of embodiments preferred by the inventor for which an enabling description was available, notwithstanding that insubstantial modifications of the invention, including those not presently foreseen, may nonetheless represent equivalents thereto. 

1. A molded plastic insert intended for use in a concrete form to make a socket in a concrete structure that is adapted for engagement with a tool, the insert having an interior bore with an open end, a closed end and two opposed channels extending longitudinally from the open end toward the closed end adapted to receive flanges of a tool, each longitudinal channel terminating near the closed end in a generally annular channel that is adapted to receive one of the tool flanges such that the tool can be prevented from extraction from the insert by a quarter turn rotation of the tool flanges in the annular channels in the manner of a bayonet lock, the insert having on an exterior surface one or more generally annular ribs and opposite longitudinal projections corresponding to the interior longitudinal channels, characterized in that: the insert is constructed from two essentially identical molded half pieces.
 2. The insert according to claim 1, wherein the insert half pieces are connected to each other along mating edges that run transversely along respective centerlines of the longitudinal projections.
 3. The insert according to claim 1, wherein each of the insert half pieces includes an inner surface defining half of the interior bore, half of each of the opposed longitudinal channels, and one of the annular channels.
 4. The insert according to claim 1, wherein each of the opposed longitudinal channels is intersected by a second generally annular channel adjacent the open end of the bore, the second annular channels being adapted for engagement by flanges of a mounting tool to hold the insert in place on a concrete form wall.
 5. The insert according to claim 4, wherein at least a portion of the second generally annular channels extends in substantially helical fashion with respect to the interior bore to provide for a thread-like engagement between the mounting tool and the insert such that the insert and mounting tool are drawn towards each other when the flanges of the mounting tool engages the second channels and the tool is rotated.
 6. The insert according to claim 2, wherein each of the insert half pieces includes a longitudinally-extending flange on the exterior surface defining one of the mating edges of half piece, the longitudinally-extending flange including at least one opening, and wherein each of the insert half pieces also includes a tab projection for each of the flange openings extending from the other one of the mating edges, the tabs and flange openings being axially aligned with each other such that the tabs of each insert half piece are received by the flange openings of the other insert half piece.
 7. The insert according to claim 6, wherein each of the insert half pieces includes an end wall at the closed end of the insert, the end wall of each insert half piece including a recess for sliding receipt of a portion of the end wall of the other insert half piece to provide a nested engagement between the insert half pieces.
 8. The insert according to claim 1, wherein each of the insert half pieces is entirely identical.
 9. An insert intended for use in a concrete form to make a socket in a concrete structure that is adapted for engagement with a tool, the insert comprising: an elongated body having an inner surface defining an interior bore extending longitudinally with respect to the body, the body including a proximal end and an opposite distal end and having an opening at the distal end communicating with the interior bore, the body also including at least one channel on the inner surface located adjacent the distal end of the body for engagement with a lifting tool for lifting a concrete member in which the insert has been installed, the body further including at least one channel spaced longitudinally toward the proximal end from the lifting tool channel for engagement with a mounting tool for supporting the insert during formation of a concrete member in which the insert is installed.
 10. The insert according to claim 9, wherein the body comprises identical halves connected to each other along a parting line, and the body including two lifting tool channels adjacent the distal end and two channels for engagement with a mounting tool.
 11. The insert according to claim 9, wherein at least a portion of each mounting tool channel extends substantially helically with respect to a central axis of the body for thread-like engagement between the mounting tool channel and a mounting tool by which the insert and mounting tool are drawn towards each other to provide a sealing barrier to concrete therebetween.
 12. A system for holding a concrete insert in a wall on a concrete form during formation of a concrete structure, the system comprising: an insert having an interior bore, an open end communicating with the interior bore and an opposite closed end, the insert including two opposed channels extending longitudinally from the open end towards the closed end adapted to receive a tool, each longitudinal channel terminating near the closed end in a generally annular channel that is adapted to receive flanges of a tool such that the tool can be prevented from extraction from the insert by a quarter turn rotation of the tool, and the insert having an additional locking channel on its inner surface intersecting one of the longitudinal channels and axially spaced from the lifting tool channels; and a mounting tool including a fixed portion adapted to be connected to a form wall and a rotatable portion including a locking member adapted to be received by the additional locking channel of the insert, the locking member and the additional locking channel being adapted to draw the insert toward the mounting when the locking member is received in the channel and the rotating portion is rotated.
 13. An insert holding system according to claim 12, wherein the locking member is a plate including a peripheral flange, and wherein the insert includes a generally annular channel on the inner surface receiving the peripheral flange of the locking member, at least a portion of the generally annular channel extending substantially helically with respect to a central axis of the insert.
 14. An insert holding system according to claim 13, wherein the fixed portion of the mounting tool includes a positioning plate located adjacent the locking plate, the positioning plate including a peripheral flange adapted to be received by one of the longitudinal channels to inhibit the insert from rotating with the locking plate.
 15. An insert holding system according to claim 12, wherein the mounting tool includes a sealing member made from a resilient material.
 16. An insert holding system according to claim 12, wherein the insert includes a generally annular rib located at the proximal end of the insert to engage against the sealing member.
 17. An insert holding system according to claim 14, wherein the rotatable portion of the mounting tool includes a locking lever to which the locking plate is secured for concomitant rotation therewith, and wherein the positioning plate of the fixed portion is rotatably received on the locking lever.
 18. An insert holding system according to claim 12, wherein the fixed portion of the mounting tool includes a body and mounting flanges extending outwardly from an outer surface of the body, the flanges adapted to support the mounting tool on a wall of the concrete form during formation of the concrete structure in which the insert is installed. 